Compliant crown panel for an aircraft

ABSTRACT

An aircraft forward pressure bulkhead and an aircraft crown panel are described herein. The forward pressure bulkhead includes a malleable and deformable dome that is configured to “catch” foreign objects, such as birds. The dome is intentionally designed to deform in response to a foreign object strike that imparts at least a threshold amount of impact energy to the bulkhead. The dome is free of rigid stiffeners and non-deformable reinforcement members that would otherwise hinder the flexible characteristic of the dome. Practical embodiments of the bulkhead utilize fewer parts, are less heavy, and are less expensive than traditional bulkheads that utilize rigid stiffeners. The crown panel has similar compliant characteristics. The crown panel is designed to simultaneously deform and deflect in response to foreign object impacts such as birds and hail. The crown panel is formed from a monolithic one-piece material, such as aluminum, and various reinforcing features are integrally formed in the material.

CROSS-REFERENCE TO RELATED APPLICATION(S)

This application is a continuation-in-part of U.S. patent applicationSer. No. 11/335,275, filed Jan. 19, 2006 now U.S. Pat. No. 7,766,277.

TECHNICAL FIELD

Embodiments of the subject matter described herein relate generally toaircraft structures. More particularly, embodiments of the subjectmatter relate to a compliant crown panel for an aircraft.

BACKGROUND

The forward pressure bulkhead in an aircraft is located at the nose ofthe fuselage, and it serves as a barrier for the pressurized interiorcabin environment. The front side of the forward pressure bulkhead istypically surrounded by the radome or “nose cone” of the aircraft, whichhouses an antenna and/or other equipment for the aircraft. The inside ofthe radome is not pressurized, i.e., it is exposed to ambient airconditions. The radome is typically formed from a lightweight andelectromagnetic transparent material such as fiberglass. Consequently,the forward pressure bulkhead is designed to provide additionalprotection against foreign objects, such as birds, which may strike thenose of the aircraft.

Conventional forward pressure bulkheads are designed to rigidlywithstand impacts by providing a “brick wall” protection mode. In otherwords, conventional forward pressure bulkheads are engineered to resistbird penetration with very low structural deflection. In this regard,such forward pressure bulkheads utilize rigid reinforcement beams, ribs,or other components that support the main bulkhead panel. Therefore,such forward pressure bulkheads are typically fabricated from manyseparate components that are welded, riveted, or otherwise connectedtogether to form the desired structure. The resulting structure caninclude a large parts count, which increases the cost of the forwardpressure bulkhead. In addition, the resulting structure is, by design,structurally inefficient.

The crown panel of an aircraft is the area beginning above the cockpitwindows and typically extending aft to a structural frame member of theaircraft. Like the forward pressure bulkhead, this area is prone to birdstrike and in-flight hail due to its exposed location near the front ofthe fuselage. In this area there is a steep angle of incidence relativeto the direction of flight (typically about 25 to 30 degrees).Conventional crown panels utilize substantial structure and frameelements designed to resist deflection and penetration by foreignobjects. Consequently, prior art crown panel assemblies utilize heavyreinforcement beams, ribs, or other components that support the exposedcrown panel skin. Moreover, such prior art crown panel assemblies mayrequire a large parts count, which increases the material andmanufacturing cost of the crown panel.

BRIEF SUMMARY

A compliant crown panel as described herein employs a malleable anddeformable skin or panel in lieu of a rigid panel and frame structure.The primary section of the crown panel is designed to deform under theimpact of a bird strike, thus absorbing and dissipating the impactenergy. In an embodiment described herein, the crown panel is formedfrom a monolithic one-piece material such as aluminum. A reinforcedperimeter and/or transverse reinforcing features are formed in theone-piece material by selectively removing material. Selective removalof material results in relatively thin areas that deform when subjectedto lower impact forces, while the relatively thick areas define thereinforcing features. Some of these reinforcing features deform whensubjected to higher impact forces. The embodiments of the crown paneldescribed herein use fewer parts and are lightweight relative toconventional aircraft crown panels and panel support structure. Forexample, embodiments of the crown panel may be 60-80 pounds lighter thantheir traditional counterparts.

The above and other aspects may be carried out by an embodiment of anenergy absorbing skin for an aircraft. The energy absorbing skinincludes a malleable panel that is configured to deform in response to athreshold amount of impact energy caused by a foreign object strike,thus absorbing and dissipating at least a portion of the impact energy.The energy absorbing skin is void of any rigid non-deformable framemembers.

The above and other aspects may be carried out by an embodiment of anenergy absorbing crown panel for an aircraft having a cockpit windowframe structure that includes at least one window post and an aft windowframe support structure. The energy absorbing crown panel includes: amalleable panel that is configured to deform in response to a thresholdamount of impact energy caused by a foreign object strike, thusabsorbing and dissipating at least a portion of the impact energy; aforward edge reinforcing feature formed in the malleable panel, theforward edge reinforcing feature being configured for coupling to theaft window frame support structure; at least one transverse reinforcingfeature formed in the malleable panel, and at least one transversereinforcing feature being configured for alignment with the at least onewindow post.

The above and other aspects may be carried out by an embodiment of anenergy absorbing skin for an aircraft. The energy absorbing skinincludes: a malleable panel formed from a monolithic one-piece materialhaving a nominal thickness, the malleable panel being configured todeform in response to a threshold amount of impact energy caused by aforeign object strike, thus absorbing and dissipating at least a portionof the impact energy; and at least one reinforcing feature formed in themonolithic one-piece material by selective removal of material andreduction of the nominal thickness near the at least one reinforcingfeature.

This summary is provided to introduce a selection of concepts in asimplified form that are further described below in the detaileddescription. This summary is not intended to identify key features oressential features of the claimed subject matter, nor is it intended tobe used as an aid in determining the scope of the claimed subjectmatter.

BRIEF DESCRIPTION OF THE DRAWINGS

A more complete understanding of the subject matter may be derived byreferring to the detailed description and claims when considered inconjunction with the following figures, wherein like reference numbersrefer to similar elements throughout the figures.

FIG. 1 is a perspective front view of a prior art aircraft forwardpressure bulkhead;

FIG. 2 is a schematic side view of an embodiment of a forward pressurebulkhead, as installed in an aircraft;

FIG. 3 is a schematic rear view of the forward pressure bulkhead shownin FIG. 2;

FIG. 4 is a perspective front view of the forward pressure bulkheadshown in FIG. 2;

FIG. 5 is a rear view of the forward pressure bulkhead shown in FIG. 2;

FIG. 6 is a cross sectional view of the forward pressure bulkhead shownin FIG. 5, as viewed along line A-A;

FIG. 7 is a perspective front view of another embodiment of a forwardpressure bulkhead;

FIG. 8 is a perspective front view of an embodiment of a compliant crownpanel, as installed on an aircraft;

FIG. 9 is a perspective front view of support and frame structures nearthe installation location of the compliant crown panel shown in FIG. 8;

FIG. 10 is a front view of an embodiment of a compliant crown panel;

FIG. 11 is a side view of the compliant crown panel shown in FIG. 10;

FIG. 12 is a rear view of the compliant crown panel shown in FIG. 10;

FIG. 13 is a cross sectional view of the compliant crown panel as viewedfrom line B-B in FIG. 12; and

FIG. 14 is a cross sectional view of the compliant crown panel as viewedfrom line C-C in FIG. 12.

DETAILED DESCRIPTION

The following detailed description is merely illustrative in nature andis not intended to limit the invention or the application and uses ofthe invention. Furthermore, there is no intention to be bound by anyexpressed or implied theory presented in the preceding technical field,background, brief summary or the following detailed description. For thesake of brevity, conventional techniques and features related toaircraft design, aircraft structures, aircraft manufacturing, and otheraspects of aircraft bulkheads and crown panels (and the individualoperating components of aircraft bulkheads and crown panels) may not bedescribed in detail herein.

The following description refers to elements or features being“connected” or “coupled” together. As used herein, unless expresslystated otherwise, “connected” means that one element/feature is directlyjoined to (or directly communicates with) another element/feature, andnot necessarily mechanically. Likewise, unless expressly statedotherwise, “coupled” means that one element/feature is directly orindirectly joined to (or directly or indirectly communicates with)another element/feature, and not necessarily mechanically.

FIG. 1 is a perspective front view of a prior art aircraft forwardpressure bulkhead 100. Bulkhead 100 is installed at the front of anaircraft adjacent to an unpressurized nose radome. Bulkhead 100maintains the pressurization inside the aircraft cabin while providing ameasure of physical protection against strikes from foreign objects suchas birds. In this regard, bulkhead 100 includes a generally flat anddisk shaped face plate 102. Face plate 102 is designed to be rigid,non-deformable, and non-malleable, such that it provides a solid and“impenetrable” wall under normal flight conditions. Notably, face plate102 is supported by a plurality of stiffening ribs 104, which providerigid reinforcement to face plate 102. The stiffening ribs 104 arephysically coupled to the exposed surface of face plate 102. Additionalstiffening ribs (hidden from view) are also located on the oppositesurface of face plate 102. These stiffening ribs 104 are intentionallydesigned to be non-deformable and non-malleable structural supportmembers for bulkhead 100. In practical deployments, the use ofstiffening ribs 104 adds to the overall parts count, expense, weight,and manufacturing complexity of bulkhead 100.

FIG. 2 is a schematic side view of a forward pressure bulkhead 200according to an example embodiment of the invention, as installed in anaircraft 202, FIG. 3 is a schematic rear view of forward pressurebulkhead 200, FIG. 4 is a perspective front view of forward pressurebulkhead 200, FIG. 5 is a rear view of forward pressure bulkhead 200,and FIG. 6 is a cross sectional view of forward pressure bulkhead 200 asviewed along line A-A in FIG. 5. Bulkhead 200 is generally configured tobe used as a forward pressure bulkhead adjacent to an unpressurized noseradome 204 of aircraft 202. Bulkhead 200 is suitably configured towithstand pressure loading when the aircraft cabin is pressurizedrelative to ambient air pressure outside the aircraft. Bulkhead 200leverages the natural characteristics of a dome shape to carry thepressure forces with a light malleable membrane rather than a heavystiffened “panel and beam” structure as depicted in FIG. 1. The domeelement is flexible enough to deform under the impact of a bird strike,thus absorbing and dissipating at least a portion of the impact energythrough plastic deformation. This characteristic of bulkhead 200addresses the need for a lightweight structure for airplanepressurization, while providing protection against foreign objectswithout resorting to the traditional “brick wall” approach. In practice,bulkhead 200 assumes a spherical shape that corresponds to the naturalpressurization forces asserted by the cabin pressure. Thus, the dome ofbulkhead 200 need only resist in a pure tensile mode, which it does in avery efficient manner. By being forgiving enough to “catch” a bird, butnot allowing penetration, bulkhead 200 provides effective protection atthe minor cost of a small amount of additional space needed toaccommodate deflections. That additional space is also balanced to somedegree by the space required to accommodate stiffeners in thetraditional approach.

FIG. 2 depicts a typical installation location for bulkhead 200. In thisexample embodiment, bulkhead 200 is slightly canted in a forwarddirection relative to the front of aircraft 202. For this exampleinstallation, bulkhead 200 may be canted approximately 5-7 degreesrelative to a vertical plane. Canting the dome allows for greater energyabsorption by allowing the bird to spread over a larger area, but is nota necessary feature of the invention. The bulkhead 200 is coupled withan outer chord 206. The purpose of the outer chord 206 is to react thetension load due to pressurization of the bulkhead membrane through hoopcompression in the ring. In other embodiments, the pressure load may bereacted by the dome itself or other parts of the aircraft structure. Inpractice, bulkhead 200 may be coupled to support and/or frame structuresof aircraft 202 such that the outer chord 206 of bulkhead 200 remainsstationary. For example, bulkhead 200 may be attached to a rigid frame208 that provides an interface between bulkhead 200, the crew floor,radome 204, and the aircraft skin. Frame 208 may be formed from anysuitable material, such as aluminum. In the example embodiment, frame208 is realized as a monolithic sub-structure that is machined from asingle piece of three inch thick aluminum plate. The specific design,configuration, and composition of frame 208 can vary to suit the needsof the given aircraft.

Referring to FIGS. 4-6, bulkhead 200 generally includes a malleable dome210 that is suitably configured to deform in response to a thresholdamount of impact energy caused by a foreign object strike. In thismanner, dome 210 can absorb and dissipate at least a portion of theimpact energy and, in practical embodiments, virtually all of the birdenergy required for FAA certification, the residual being absorbed bythe underlying aircraft structure. Notably, bulkhead 200 and dome 210are void of any rigid non-deformable reinforcement members (in contrastto conventional designs that utilize stiffener members). Moreover, dome210 includes no holes or penetrations other than fastener locations nearthe perimeter edge of bulkhead 200. In the example embodiment, dome 210is formed from an aluminum alloy, such as 2024-T3 aluminum. Of course,dome 210 may be formed from other suitable materials, alloys, andcompositions, including KEVLAR, SPECTRA, ZYLON, fiberglass,thermoplastics such as PEEK and PEKK, or virtually any practicalmaterial. Material with higher plastic strain to failure and higherstrength will typically absorb more energy, but bulkhead 200 may beconfigured to allow for significant energy absorption through elastic aswell as plastic deflection of the dome 210. In practice, dome 210 can begenerally shaped as a spherical cap (i.e., a section of a sphericalshell) having a convex front surface 212 and a concave aft surface 214.In this example, dome 210 is formed with a spherical radius ofapproximately 120 inches, the diameter at the base of dome 210 isapproximately 85.4 inches, and the depth of dome 210 is approximatelyeight inches. Dome 210 is configured to withstand pressurized airloading applied to concave aft surface 214 relative to ambient airpressure exposed to convex front surface 212. Such differential pressureconditions occur during normal operation of the aircraft.

Dome 210 may be formed from a single sheet of material. Multiple layersare not a necessary feature of the invention, in practical embodiments,however, dome 210 is realized as a multilayered component to provide afailsafe measure for bulkhead 200. In this example, dome 210 includes afirst full layer 216, a second full layer 218 coupled to first fulllayer 216, and a partial layer 220 coupled to second full layer 218. Thelayers can be attached together using any suitable mechanism ortechnique, such as cold bonding, hot bonding, mechanical fasteners,welding, clamps, or the like. The first and second layers are “full”relative to partial layer 220, which does not span the entire surface ofdome 210. In other words, the first and second layers are “redundant”layers because they each generally define a spherical cap. Partial layer220, however, generally defines a truncated spherical cap, or a ringshaped layer having a spherical contour. Dome 210 includes an outerperimeter 222 that is generally defined by its circular edge. As shownin FIG. 5 and FIG. 6, partial layer 220 is located around outerperimeter 222. In other words, partial layer 220 forms a ring layer thatcircles the periphery of second full layer 216. Thus, the exposed outersurface of first full layer 212 represents convex front surface 212,while the exposed outer surface of second full layer 218, along with theexposed outer surface of partial layer 220, represents concave aftsurface 214. Thus, first full layer 216 generally corresponds to thefront side of bulkhead 200, and partial layer 220 generally correspondsto the aft side of bulkhead 200.

First full layer 216, second full layer 218, and partial layer 220 areeach formed from a ductile and deformable material, which facilitatesthe impact energy absorbing and dissipating properties of bulkhead 200as described above. In one practical embodiment, first full layer 216and second full layer 218 are each formed from a sheet of aluminum thatis approximately 0.063 inch thick. In particular, these full layers maybe formed from a seamless sheet of 2024-T3 aluminum alloy. Partial layer220 may also be formed from a seamless sheet of 2024-T3 aluminum alloy.In the example embodiment, partial layer 220 has a variable thicknessthat decreases towards the center of dome 210. For ease ofmanufacturing, the variable thickness may (but need not be) be formed indiscrete steps, as depicted in FIG. 6. In this regard, partial layer 220has an outer edge 224 located toward outer perimeter 222, and an inneredge 226 located toward the center of dome 210. Inner edge 226 isapproximately 14-17 inches from outer edge 224 in this embodiment (inone practical embodiment, partial layer 220 is about 15.7 inches wide).Outer edge 224 may have a thickness of approximately 0.125 inch, andinner edge 226 may have a thickness of approximately 0.031 inch. Inpractice, partial layer 220 may include any number of intermediate stepshaving decreasing thicknesses between outer edge 224 and inner edge 226.The relatively thick portion of dome 210 near outer perimeter 222 isdesirable to provide additional strength for mounting of bulkhead 200.The variation in shell thickness of dome 210 also provides additionalresistance to impact stresses near the edge of dome 210. Stresses arehigher toward the edge due to reduced compliance of the dome 210 inthose areas.

Dome 210 (and any layer thereof) may be formed using any suitablemanufacturing technique. For example, dome 210 may be manufactured usinga bulge forming technique that applies pressure to a flat sheet to shapethe spherical cap. Alternatively, dome 210 may be manufactured using aspin forming technique that rotates a flat sheet while applying pressurewith a forming tool to create a dished shape. Dome 210 may also beformed using stamping, stretch forming, or pressing techniques.

Bulkhead 200 also includes an outer chord 228 that is coupled to dome210 around outer perimeter 222. In this embodiment, the outer chord 228is composed of multiple segments of 7075 T73 aluminum formed such thatits cross section is an angle formed by one leg that matches the contourof the dome 210 and a secondary leg that matches the contour of thefuselage. The purpose of the angle is to integrate the dome 210 to thefuselage and to lend stiffness to the outer chord 228 such that itresists compression loads caused by membrane tension in the dome 210.

Outer chord 228 is suitably configured to provide a rigid attachmentmechanism for bulkhead 200. Referring again to FIG. 2 and FIG. 3, outerchord 228 can be utilized to attach bulkhead 200 to frame 208, awindshield support, and/or other structures of aircraft 202. Outer chord228 may also be configured to accommodate attachment of the aircraftfuselage skin. As depicted in FIG. 2 and FIG. 4, outer chord 228 mayalso provide attachment points for an antenna support assembly 229.Notably, antenna support assembly 229 need not be attached to dome 210itself. Rather, antenna support assembly 229 preferably forms a “bridge”over dome 210. Indeed, bulkhead 200 is preferably configured such thatno rigid stiffeners or reinforcement members are directly attached toeither side of dome 210, thus making dome 210 free to deflect and deformin response to a foreign object strike.

In a practical embodiment, outer chord 228 can be formed from anysuitable material, for example, aluminum alloy 7075-T7351 or aluminumalloy 7050-T7451. For ease of manufacturing and assembly, outer chord228 may be realized as a segmented component that is spliced together.FIG. 5 shows outer chord 228 in three segments joined by three splicingelements 230. Outer chord 228 is coupled to dome 210 using suitablefasteners or fastening techniques, such as bolts, rivets, clamps,bonding, welding, or the like. In turn, bulkhead 200 is coupled toaircraft 202 (via outer chord 228) using suitable fasteners or fasteningtechniques, such as bolts, rivets, clamps, bonding, welding, or thelike.

An aircraft forward pressure bulkhead configured in accordance with analternate embodiment of the invention may employ at least one malleableand deformable tear strap layer coupled to a malleable dome (asdescribed above). In other embodiments the tear strap layer could alsobe composed of malleable or deformable stiffeners. The malleable anddeformable tear strap layer or stiffener layer is configured to retardfatigue and dynamic crack growth of the malleable dome while remainingflexible enough to accommodate the impact energy absorbing anddissipating characteristics of the bulkhead. FIG. 7 is a perspectivefront view of a forward pressure bulkhead 300 according to one suchalternate embodiment. Bulkhead 300 shares a number of features withbulkhead 200; such common features and aspects will not be redundantlydescribed herein. Bulkhead 300 includes a malleable dome 301 having atleast a first full layer 302 and at least one malleable and deformabletear strap layer 304 coupled to full layer 302. In this exampleembodiment, bulkhead 300 includes a web layer 306 coupled to full layer302, where the at least one tear strap layer 304 is defined by web layer306. In other words, web layer 306 includes tear strap layer 304, thusresembling a spider web. Web layer 306 itself is deformable andmalleable, which enables bulkhead 300 to absorb and dissipate impactenergy in the manner described above. Thus, web layer 306 may beemployed to enhance the structural integrity of bulkhead 300 in aforgiving manner in contrast to prior art techniques that rely on arigid, non-deformable, “brick wall” configuration.

A practical embodiment of the aircraft forward pressure bulkheaddescribed herein is designed to withstand a strike from a four poundobject traveling at cruise velocity (Vc) at sea level or 0.85 Vc at 8000feet, whichever is critical, as required by Federal Aviation Regulation§25.571. This and other embodiments of the invention may withstanddiffering bird weights and velocities depending on the requirement. Inpractice, the bulkhead has a threshold impact energy rating thatdetermines whether the bulkhead dome will deform and deflect in responseto the impact. The curved and angled surface of the bulkhead increasesthe likelihood that objects will deflect away from the dome. If anobject strikes the bulkhead without imparting at least that thresholdimpact energy, then the object will either bounce off of the dome ordeflect away from the dome. Under such conditions, the dome maytemporarily deflect inward then snap back to its original shape. If,however, an object strikes the bulkhead with at least the thresholdimpact energy, then the dome will “catch” the object, deflect inward,and deform in a manner that absorbs and dissipates the impact energy. Inthis regard, the dome buckles under the impact force of the object,which travels a short distance in the aft direction after contact withthe dome. The malleable nature of the dome enables the bulkhead todissipate the impact force over a longer impact time (relative to rigidand stiff bulkheads). The dome may remain in a buckled or bent shapeafter impact, or it may snap back to its original shape. If the internalpressure does not restore the original shape of the bulkhead, it maythen be restored by physical manipulation, or it may be replaceddepending upon the severity of the deformation. The simple construction,light weight, and relatively low cost of the bulkhead enable suchbulkheads to be sacrificial components.

The general characteristics of the compliant bulkhead described abovemay also be realized using other energy absorbing skins or panels of anaircraft, such as a crown panel. The basic function of an aircraft crownpanel is to contain pressure and provide resistance against in-flightbird and hail hazards. The crown panel embodiments described hereinperform this basic function at a reduced weight and cost relative toconventional crown panels and supporting structure. These benefits arederived from the use of a malleable domed panel that is designed todeform after a threshold amount of impact energy is applied. Theresulting deflections are very large relative to conventional crownpanels—one or two orders of magnitude larger. The larger deflectioneffectively reduces the applied impact force since energy is a functionof force times deflection.

The crown panels described herein are designed to withstand foreignobject strikes through large deflections that reduce the force impulseand stagnation pressure on the structure. In practice, three physicaleffects are at work. First, the impact energy is absorbed over a longerdeflection stroke, so the peak force of the impulse is lower. Second, abird will have time to spread out, which reduces stagnation pressure atthe end of the stroke—since the crown panel is compliant, very littlereaction occurs at the boundary until the end of the stroke (for acenter impact), and at the end of the stroke the reaction forces arespread around a large portion of the perimeter of the panel rather thanat the nearest adjacent frame/stringer members. Third, part of theinitial energy is absorbed through flexure of the material but some isalso absorbed by the acceleration of the target mass (for centerimpacts), and the initial energy eventually unwinds at the boundary butthe effect is to reduce the peak impulsive force.

The crown panels described herein are simple in form relative toconventional crown panel designs. In lieu of the traditional skin andassociated stiffening members, a crown panel as described herein employsa lofted panel having a reinforced boundary. The crown panel ispreferably formed such that it has a tapered and non-uniform crosssection that is thinner toward the center of the panel. For theillustrated embodiment, the non-uniform cross section may be createdusing chemical milling processes. For fail-safety, a crown panel mayinclude a system of tear straps or a bonded second membrane (not shown).The tear straps allow crack arrestment without the added stiffness offrames or stringers so that malleability and the compliant nature of thecrown panel is maintained.

FIG. 8 is a perspective front view of an embodiment of a compliant crownpanel 400 as installed on an aircraft 402, and FIG. 9 is a perspectivefront view of support and frame structures near the installationlocation of crown panel 400. For clarity, crown panel 400 is not shownin FIG. 9. FIG. 8 depicts the portion of aircraft 402 near the cockpit(see also FIG. 2). This particular embodiment of aircraft 402 utilizes acockpit window frame structure that includes a right (starboard) windowpost 404, a left (port) window post 406, a center window post 408between right window post 404 and left window post 406, and an aftwindow frame support structure 410. These elements of the cockpit windowframe structure may be formed from aluminum, titanium, or any suitablematerial having the necessary structural properties. These elementsfacilitate mounting of cockpit windows 412 to aircraft 402.

For this example, crown panel 400 is located between aft window framesupport structure 410 and another frame support structure 414 of theaircraft (see FIG. 9). In this regard, crown panel 400 may includeintegral reinforcing features that are suitably configured for couplingto aft window frame support structure 410, frame support structure 414,and/or other mounting elements of aircraft 402. In practice, theboundary of crown panel 400 is formed to be stiffer than the mainsection of crown panel 400 to resist impact through strength rather thancompliance. This characteristic is desirable for the boundary, whichserves as a junction between the compliant section of crown panel 400and the rigid aircraft support structures. Moreover, the boundary mayrequire additional strength to accommodate fasteners for crown panel400.

Crown panel 400 spans a section of aircraft 402 having a relativelysteep angle of incidence relative to the direction of travel, while thesection of aircraft 402 behind frame support structure 414 has arelatively low angle of incidence, thus making it less susceptible tobird strike damage. Notably, crown panel 400 need not (and preferablydoes not) include or utilize any heavy, rigid, and non-deformable framemembers, which are characteristic of conventional crown panel designs.Referring to FIG. 9, the space 416 between aft window frame supportstructure 410 and frame support structure 414 is void of any structuralsupport members for crown panel 400. In contrast, conventional crownpanels would require a “web” of rigid and stiff cross members in space416; this web serves as a structural backing for the conventional crownpanel skin, and this web is designed such that the conventional crownpanel functions like a rigid “wall” to resist deformation or penetrationby foreign objects. In practical deployments, the use of this stiffeningweb adds to the overall parts count, expense, weight, and manufacturingcomplexity of the crown panel and the aircraft.

The support elements depicted in FIG. 9 have been simplified toillustrate that crown panel 400 need not be supported or backed by anyrigid structural stiffening members. In practice, aircraft 402 mayinclude support elements within space 416, where such support elementsare utilized for aircraft systems and hardware. Thus, equipment thatmight otherwise be mounted to or behind a conventional crown panel isremounted on the surrounding aircraft structure and far enough fromcrown panel 400 panel to avoid damage to sensitive or criticalcomponents. Such equipment supporting elements are not shown in thefigures because they are unrelated to the configuration or operation ofcrown panel 400.

FIG. 10 is a front view of an embodiment of a compliant crown panel 500,FIG. 11 is a side view of crown panel 500, FIG. 12 is a rear view ofcrown panel 500, FIG. 13 is a cross sectional view of crown panel 500 asviewed from line B-B in FIG. 12, and FIG. 14 is a cross sectional viewof crown panel 500 as viewed from line C-C in FIG. 12. For compatibilitywith one aircraft deployment, crown panel 500 has a width of about 100inches (the longest dimension in FIG. 10 or FIG. 11) and a fore-aftlength of about 57 inches (the dimension of the “peak” of crown panel500, which is best shown in FIG. 11).

Crown panel 500 is one example of an energy absorbing skin suitable foran aircraft. Crown panel 500 is suitably configured to withstandpressure loading when the aircraft cabin is pressurized relative toambient air pressure outside the aircraft. Crown panel 500 leverages thenatural characteristics of a concave shape to carry the pressure forceswith a light malleable membrane rather than a heavy stiffened “panel andbeam” structure as utilized by conventional crown panels. Indeed,preferred embodiments of crown panel 500 are void of any rigidnon-deformable frame members. Crown panel 500 is flexible enough todeform under the impact of a bird (or other foreign object) strike, thusabsorbing and dissipating at least a portion of the impact energythrough elastic and plastic deformation. More specifically, crown panel500 is suitably configured to deform in response to a threshold amountof impact energy caused by a foreign object strike, thus absorbing anddissipating at least a portion of the impact energy. This characteristicof crown panel 500 addresses the need for a lightweight structure forairplane pressurization, while providing protection against foreignobjects without resorting to the traditional “rigid wall” approach. Inpractice, crown panel 500 is compliant enough to simultaneously deformand deflect upon a bird strike, without allowing penetration.

Referring to FIGS. 10-12, crown panel 500 has a generally convex outersurface 502 and a generally concave inner surface 504 (see FIG. 8, whichillustrates the overall contour of crown panel 400). For the illustrateddeployment, convex outer surface 502 represents an exterior surface ofthe aircraft and, therefore, convex outer surface 502 is preferablysmooth and seamless. Concave inner surface 504 may be subjected tointerior cabin pressure established by the aircraft. In this regard,crown panel 500 is suitably configured to withstand pressurized airloading applied to concave inner surface 504 relative to ambient airpressure that is exposed to convex outer surface 502. As described inmore detail below, concave inner surface 504 includes a number offeatures formed therein.

Crown panel 500 generally includes, without limitation: an outerperimeter defined at least in part by a forward edge 506, side edges508, and an aft edge 510; a forward edge reinforcing feature 512; sideedge reinforcing features 514; an aft edge reinforcing feature 516; aright (starboard) transverse reinforcing feature 518; a left (port)transverse reinforcing feature 520; and a center transverse reinforcingfeature 522. For this embodiment of crown panel 500, the variousreinforcing features are integrally formed in crown panel 500. In otherwords, these reinforcing features need not be realized as separate anddistinct physical elements, and crown panel 500 can be manufacturedwithout assembling multiple parts together.

This embodiment of crown panel 500 is configured as a malleable anddeformable panel that is formed from a monolithic one-piece material(other embodiments may utilize more than one piece). As depicted in FIG.10, the one-piece nature of crown panel 500 results in a seamlessmalleable panel having a smooth outer surface. The material used tomanufacture crown panel 500 may be, for example, titanium, aluminum, ametal alloy, an epoxy-graphite composite, an epoxy-fiberglass composite,a thermoplastic-graphite composite, a thermoplastic-fiberglasscomposite, or the like. In one practical embodiment, crown panel 500 isformed from 2024-T3 or 2024-T42 aluminum stock. Although any suitablematerial can be used, 2024-T3 aluminum is preferred in impact areas dueto its high strain-to-failure characteristics, fatigue resistance, andlow cost. In practice, the monolithic material used for crown panel 500initially has a nominal and uniform thickness before machining orchemical milling, which also represents the maximum thickness of crownpanel 500 after machining or chemical milling. In this example, thenominal thickness is about 0.375 inches. Reference number 524 in FIG. 13and FIG. 14 represents this nominal thickness.

Right transverse reinforcing feature 518, left transverse reinforcingfeature 520, and center transverse reinforcing feature 522 areintegrally formed in the monolithic one-piece material used for crownpanel 500. The transverse reinforcing features are formed in the concaveinner surface 504 of crown panel 500. Each transverse reinforcingfeature is preferably formed such that it remains malleable anddeformable when subjected to the anticipated impact energy caused by aforeign object strike. In other words, these transverse reinforcingfeatures are intentionally designed to deform and deflect in response toa threshold amount of impact energy, and they are not intended tofunction as stiff and rigid non-deformable structural beams. Thesemalleable and deformable reinforcing features are suitably configured toenhance fail safety of crown panel 500 and to absorb and dissipate theimpact energy caused by bird strikes and other impact hazards. Inaddition, these reinforcing features serve as crack resistant membersthat function to impede crack growth that might originate in the thinnersections of crown panel 500. In this embodiment the reinforcing featuresare formed from the monolithic one-piece material, however otherembodiments may utilize separate fastened or bonded straps as crackarrestment features. Such features would be similar to those describedand depicted for the forward pressure bulkhead.

As described above with reference to FIG. 8 and FIG. 9, an aircraft mayinclude a number of window posts for the cockpit windows. In thisregard, the transverse reinforcing features of crown panel 500 may besuitably configured for alignment with such window posts. For example,right transverse reinforcing feature 518 is located such that it alignswith a right window post after installation, left transverse reinforcingfeature 520 is located such that it aligns with a left window post afterinstallation, and center transverse reinforcing feature 522 is locatedsuch that it aligns with a center window post after installation. Thisconfiguration is desirable because it establishes continuous load pathsfrom the window posts to remaining structure of the aircraft. Thiswindow post alignment is illustrated in FIG. 8—right transversereinforcing feature 518 is positioned such that it serves as an“extension” of right window post 404, left transverse reinforcingfeature 520 is positioned such that it serves as an “extension” of leftwindow post 406, and center transverse reinforcing feature 522 ispositioned such that it serves as an “extension” of center window post408. The transverse reinforcing features are depicted in dashed lines inFIG. 8 because they would otherwise not be visible.

Each transverse reinforcing feature is preferably formed with a taperedcross section, as depicted in FIG. 14 (which is a cross sectional viewof center transverse reinforcing feature 522 taken along line C-C inFIG. 12). This tapered cross section is desirable to enable thetransverse reinforcing features to be compliant and malleable, whileresistant to ripping or tearing at the junctions with the thinnersections of crown panel 500. For this embodiment, center transversereinforcing feature 522 maintains the nominal thickness 524 of themonolithic material along its longitudinal transverse axis. Notably,center transverse reinforcing feature 522 gradually becomes thinner onboth sides until it reaches the primary area of crown panel 500, whichrepresents a relatively thin section. In this example, center transversereinforcing feature 522 tapers down to a thickness of about 0.175 inches(which corresponds to the thickness of the primary area of crown panel500). Reference number 526 in FIG. 13 represents this 0.175 inchthickness.

The taper angle need not be uniform along the length of a transversereinforcing feature, the taper angle need not be uniform for alltransverse reinforcing features, and the taper angle profile of atransverse reinforcing feature need not be the same on both sides. Forexample, the taper angle of center transverse reinforcing feature 522may be less than the taper angle of right transverse reinforcing feature518 and left transverse reinforcing feature 520 to accommodate moredeformation near the middle of crown panel 500. As another example, thetaper angle on the inner side of right/left transverse reinforcingfeature 518/520 may be steeper than the taper angle on the outer side ofright/left transverse reinforcing feature 518/520. The tapers are usedfor two primary purposes. First, there is a minimum required taper angleto meet fatigue requirements. In this embodiment, the reinforcingfeatures 518, 520, and 522 are in a zone which has relatively morecompliance than the edges 506, 508, and 510. These perimeter edge areasare adjacent to stiffening members required for cockpit window surroundand escape hatch features and are therefore less compliant. As such, inflight damage such as that caused by bird strike is much more likelynear the perimeter. The crown panel can be designed and configured totailor the gradation of the taper in each particular zone. If thegradation near a stiffening feature such as a frame is too steep,penetration may be more likely where the “basic” skin gauge meets thetaper. Reinforcing features 518, 520, and 522 are tapered at the minimumrequired gradation for fatigue. The tapering characteristics andprofiles of the transverse reinforcing features can be adjustedaccording to the anticipated impact loading and according to the desireddeflection and deformation characteristics of crown panel 500.

As mentioned above, this embodiment of crown panel 500 is formed from amonolithic one-piece material (such as aluminum) having a nominalthickness. The transverse reinforcing features may be integrally formedin crown panel 500 by selective removal of material and reduction of thenominal thickness near the malleable and deformable transversereinforcing features. In other words, material from the stock materialis selectively removed such that the remaining material defines thetransverse reinforcing features and, if applicable, the tapered crosssectional characteristics of the transverse reinforcing features. Inaccordance with one practical embodiment where the monolithic one-piecematerial is a metal, the transverse reinforcing features are chemicallyetched into the material. Referring to FIG. 12 and FIG. 13, multiplemasking and etching steps may be utilized to form the stepwise andgradual taper described above.

Referring again to FIG. 8 and FIG. 9, crown panel 500 may be configuredsuch that forward edge 506, side edges 508, and aft edge 510 (or areasnear these edges) are coupled to various frame support structures of theaircraft. Thus, forward edge reinforcing feature 512, side edgereinforcing features 514, and aft edge reinforcing feature 516 may besuitably configured for coupling to respective frame support structures.For example, forward edge reinforcing feature 512 may be designed to becoupled to aft window frame support structure 410 depicted in FIG. 9.These edge reinforcing features provide additional structural supportfor the transition between the main compliant area of crown panel 500and the rigid and non-compliant frame structure of the aircraft.Moreover, these edge reinforcing features may be configured toaccommodate fasteners used to install crown panel 500 (e.g., aluminum ortitanium bolts, screws, or rivets).

For this embodiment of a crown panel, forward edge reinforcing feature512, side edge reinforcing features 514, and aft edge reinforcingfeature 516 are integrally formed in the monolithic one-piece materialused for crown panel 500. These edge reinforcing features are preferablyformed in the manner described above for the transverse reinforcingfeatures. Common features, characteristics, and manufacturing techniqueswill not be redundantly described here in the context of the edgereinforcing features.

Briefly, the edge reinforcing features may be formed in the monolithicone-piece material by selective removal of material as described above.FIG. 13 is a cross sectional view of aft edge reinforcing feature 516 asviewed from line B-B in FIG. 12. FIG. 13 illustrates one suitabletapering profile for aft edge reinforcing feature 516. Notably, aft edgereinforcing feature 516 transitions from the nominal thickness 524 tothe reduced thickness 528 that represents the thickness of the primarycompliant area of crown panel 500.

In contrast to the transverse reinforcing features, the edge reinforcingfeatures need not be malleable and deformable because they serve as themounting boundary of crown panel 500. This mounting boundary joins therigid and non-deformable support structure of the aircraft. Therefore,the edge reinforcing features are preferably configured to provide astiff and rigid outer perimeter for crown panel 500. In practicalembodiments, crown panel 500 may be designed to flex at the center asmuch as possible without causing impact with critical equipment mountedunder crown panel 500, in contrast to the perimeter, which may flex onlyminimally due to integrated reinforcement features.

The tapered profile of the edge reinforcing features is utilized toprovide a transition between the compliant primary area of crown panel500 and the perimeter of crown panel 500. In certain embodiments, thetapering of the edge reinforcing features can be blended with thetapering of the transverse reinforcing features (see FIG. 12). Moreover,as described above for the transverse reinforcing features, the taperangle of an edge reinforcing feature need not be uniform along itslength, the taper angle need not be uniform for all edge reinforcingfeatures, and the taper angle profile of an edge reinforcing featureneed not be the same on both sides. The tapering characteristics andprofiles of the edge reinforcing features can be adjusted according tothe anticipated impact loading, the desired deflection and deformationcharacteristics of crown panel 500, and the intended installationenvironment for crown panel 500.

Crown panel 500 can be manufactured in the following manner. The stockof material (e.g., an aluminum plate) is cut into the desired size andshape. The material is then stretch-formed over an appropriatelyconfigured tool until the material assumes the desired contoured shape.At this point the material can be machined to form the desired edgeprofile and to form holding tabs that will be used for the chemicaletching process. Thereafter, the reinforcing features can be formed viaa suitable chemical etching process, which may involve multiple maskingand etching steps. After completion of the chemical etch, the materialis cleaned and the holding tabs are removed. In this manner, themonolithic one-piece material is transformed into crown panel 500. Itshould be appreciated that alternative manufacturing techniques anddifferent processing steps may be utilized to form crown panel 500; thisbrief description represents only one possible manufacturing technique.

An alternate embodiment of a crown panel having the compliantcharacteristics described herein may be realized with a compositeconstruction having an inner skin and an outer skin. For example,certain embodiments may be formed from a laminate composite constructionthat does not include a core, while other embodiments may be formed froma construction having an inner skin, and outer skin, and a core materialsandwiched between the skins. The structure may be an unstiffened,honeycomb-stiffened, or core-stiffened panel designed to invert ordeform on impact. A metallic embodiment utilizes aluminum skins and analuminum honeycomb core, where crushing of the core absorbs the impactenergy of a foreign object strike. In such an embodiment, a pad-up orother reinforcing feature is included around the perimeter (as describedabove for the monolithic embodiment) to prevent penetration innoncompliant areas.

A composite embodiment may utilize carbon fiber skins and a suitablecore material between the skins. In such a composite embodiment, extraplies or layers of material may be required around the perimeter inorder to contain impact in noncompliant areas. Alternatively, laminatestrips could be bonded around the perimeter. In addition, the use of adeformable hinge along the perimeter would allow both the composite andcomposite honeycomb embodiments to better absorb the impact with minimaldamage. Functionally, a deformable hinge can be created with any metalthat offers a failure strain high enough to plastically deform withoutfracture through the required rotational deflection of the hinge. Therotational deflection angle will depend on the convexity of the crownpanel. If the dome makes an angle theta with its chord, then therequired angular deflection will be twice theta. In this embodiment, theframe aft of the crown panel provides a convenient attachment point andwith proper material selection, a deformable hinge.

In the composite embodiment additional plies can be interleaved in orderto provide fail safety against a running crack while in the compositehoneycomb embodiment tear straps may not be required due to theredundancy provided by dual skins (i.e., the inner and outer facesheets).

While at least one example embodiment has been presented in theforegoing detailed description, it should be appreciated that a vastnumber of variations exist. It should also be appreciated that theexample embodiment or embodiments described herein are not intended tolimit the scope, applicability, or configuration of the claimed subjectmatter in any way. Rather, the foregoing detailed description willprovide those skilled in the art with a convenient road map forimplementing the described embodiment or embodiments. It should beunderstood that various changes can be made in the function andarrangement of elements without departing from the scope defined by theclaims, which includes known equivalents and foreseeable equivalents atthe time of filing this patent application.

1. An energy absorbing skin for an aircraft, the energy absorbing skincomprising: a malleable panel that is configured to deform in responseto a predetermined threshold amount of impact energy caused by a foreignobject strike so as to absorb at least a portion of the impact energy,the energy absorbing skin being void of any rigid non-deformable framemembers inward of edges of said malleable panel; said malleable panel isa monolithic one-piece material and further comprises a relativelythicker reinforcing feature including a first reinforcing featureextending along edges of the malleable panel and a second reinforcingfeature extending transverse to the malleable panel, the reinforcingfeature being stiffer than the malleable panel, and the malleable paneland the reinforcing feature configured so that both the malleable paneland the reinforcing feature deform in response to the predeterminedthreshold amount of impact energy.
 2. The energy absorbing skinaccording to claim 1, wherein the malleable panel is a crown panel. 3.The energy absorbing skin according to claim 1, wherein the monolithicone-piece material is aluminum.
 4. The absorbing skin according to claim1, wherein: the monolithic one-piece material has a nominal thickness.5. The energy absorbing skin according to claim 1, wherein the at leastone reinforcing feature comprising the malleable panel comprises adeformable reinforcing feature being configured to enhance fail safetyof the energy absorbing skin.
 6. The energy absorbing skin according toclaim 1, wherein: the malleable panel comprises a convex outer surfaceand a concave inner surface; the malleable panel is configured towithstand pressurized air loading applied to the concave inner surfacerelative to ambient air pressure exposed to the convex outer surface,and wherein the shape of the malleable panel substantially correspondsto a dome section.
 7. The energy absorbing skin according to claim 1,wherein the malleable panel is seamless.
 8. The energy absorbing skinaccording to claim 1, wherein an angle of said taper is different for atleast two of said reinforcing features.
 9. The energy absorbing skinaccording to claim 1, wherein an angle of said taper is nonuniform alonga length of said reinforcing feature.
 10. The energy absorbing skinaccording to claim 1, wherein said reinforcing feature comprises saidtaper on each side of said reinforcing feature.
 11. The energy absorbingskin according to claim 1, wherein an angle of said taper is differenton said each side of said reinforcing feature.
 12. The energy absorbingskin for an aircraft of claim 1, wherein the reinforcing feature istapered.
 13. An energy absorbing crown panel for an aircraft configuredto deform in response to a predetermined threshold amount of impactenergy caused by a foreign object strike, said energy absorbing skincomprising: a malleable panel without any rigid non-deformable framemembers inward of edges of said malleable panel; said malleable panelcomprises a monolithic one-piece material having a relatively thickerreinforcing feature including a first reinforcing feature extendingalong edges of the malleable panel and a second reinforcing featureextending transverse to the malleable panel, the reinforcing featurebeing stiffer than the malleable panel; and the malleable panel thereinforcing feature configured so that both the malleable panel and thereinforcing feature deform in response to the predetermined thresholdamount of impact.
 14. The energy absorbing crown panel according toclaim 13, wherein the monolithic one-piece material is aluminum.
 15. Theenergy absorbing crown panel according to claim 13, wherein: themalleable panel comprises a convex outer surface and a concave innersurface; the malleable panel is configured to withstand pressurized airloading applied to the concave inner surface relative to ambient airpressure exposed to the convex outer surface, and wherein the shape ofthe malleable panel substantially corresponds to a dome section.
 16. Theenergy absorbing crown panel according to claim 13, wherein themalleable panel is seamless.
 17. The energy absorbing crown panelaccording to claim 13, wherein an angle of said taper is different forat least two of said reinforcing features.
 18. The energy absorbingcrown panel according to claim 13, wherein an angle of said taper isnonuniform along a length of said reinforcing feature.
 19. The energyabsorbing crown panel according to claim 13, wherein said reinforcingfeature comprises said taper on each side of said reinforcing feature.20. The energy absorbing crown panel according to claim 13, wherein anangle of said taper is different on said each side of said atreinforcing features.
 21. The energy absorbing crown panel according toclaim 13, wherein the reinforcing feature is tapered.